Service Manual

SERVICE MANUAL

SG-3R40 SG-3C41 SG-3D55

Ver.1.0 ©Jun. 2019 by Shimano Inc. ITP CONTENTS

Introduction of INTER-3 / Explain the technologies ………………………… 2 Dealer's Manual ………………………………………………………………………………………………………………………… 3 SG-3R40, SG-3C41, SG-3D55 • INSTALLATION • MAINTENANCE Troubleshooting ………………………………………………………………………………………………………………………… 31 Disassembly & Assembly ………………………………………………………………………………………………… 33 Tools Disassembly of the Inter-3 hub (Roller Brake Spec.) Assembly of the Inter-3 hub (Roller Brake Spec.) Service Parts …………………………………………………………………………………………………………………………………… 45 Interchangeability …………………………………………………………………………………………………………………… 47 Hub dimensions…………………………………………………………………………………………………………………………… 49 EV / Spare Parts List ………………………………………………………………………………………………………………… 51

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SG-3R40 SG-3C41 SG-3D55 INTER-3 Rear Hub (3-speed) INTER-3 Rear Hub (3-speed) INTER-3 Rear Hub (3-speed) • Internal Gear Shifting • Internal geared hub for Coaster Brake version • Internal geared hub for Disc Brake version » Gear shifting action is independent of pedaling. • Integral Coaster Brake • Gear Change Support Mechanism You can shift gears anytime, while standing still, • Gear Change Support Mechanism • Aluminum hub shell pedaling or coasting • Weight: 1,120g • CENTER LOCK Rotor mount system • Gear Change Support • Weight: 945g • Weight: 885g • Color options: Black, Silver • Color options: Black, Silver, White

TECHNOLOGIES Gear Change Support SHIMANO gear change support mechanism utilizes some portion of pedaling force at down shifting. The result is a quick and precise downshift with very light feeling.

Coaster Brake The SHIMANO NEXUS coaster brake is operated by pedaling backward in a similar way as ordinary types. Its uniqueness is that braking power transmitted to the wheel directly for the SHIMANO NEXUS internal coaster brake is independent of the gear shifting mechanism built into the hub. Also it always generates the same braking force regardless of gear position to actualize comfortable and reliable riding. It actualizes the braking force to meet the ISO 4210 standard.

Equal braking force in each gear

Sprocket

Actuator Hub shell

Brake shoe

Brake roller Braking cam

Surface Treatment What is the difference between the Standard and the DX version? • The Standard version is designed to use under normal climate conditions. • The DX version features a clear coated finish and/or stainless steel material. This finish is offering an advanced protection against corrosion and is therefore recommended to use under more severe climate conditions.

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Dealer's Manual

SG-3R40 SG-3C41 SG-3D55

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WARNING

When securing the brake arm to the frame, be sure to use an arm clip that matches the size of the chainstay, and securely tighten it with the clip bolt and clip nut to the specified tightening torque. Use a lock nut with a nylon insert (self-locking nut) for the clip nut. It is recommended that Shimano made clip bolts, clip nuts, and arm clips be used. Use an arm clip that matches the chainstay. If the clip nut comes off the brake arm, or if the clip bolt or arm clip becomes damaged, the brake arm may rotate on the chainstay and cause the handlebars to jerk suddenly, or the bicycle wheel may lock and the bicycle fall over, causing serious injury.

INSTALLATION

Installation of the lever

Installation of the REVOSHIFT lever

Install the brake lever (B). (A) Brake lever band (B) Brake lever (z) Use Φ22.2 mm handlebars. (C) Handlebar (A) (B)

Tightening torque 1 6 - 8 N·m

(z) TECH TIPS (C)

Use a brake lever with a band having a thickness of 4.3 mm or lower to prevent the brake lever and REVOSHIFT lever from interfering with each other.

(A) Install the REVOSHIFT lever (A). (A) REVOSHIFT lever

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Install the half grip (A). (A) Half grip (B) Gap between the REVOSHIFT lever Leave a gap (B) of 0.5 mm between the and the half grip REVOSHIFT lever and the half grip.

3 (A)

(B)

Tighten the REVOSHIFT lever. (A) Fixing bolt

Tightening torque 4 2 - 2.5 N·m

2 - 4 N·m

(A)

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Installation of the bell crank type hub

Installation of the shifting cable

(A) Insert the outer casing into the outer (A) Outer casing holder casing holder (A).

Fit the inner cable into the link (B) in the (A) Cable adjustment barrel bell crank. (B) Link (C) Inner cable mounting plate Loosen the inner cable mounting nut (D) (D) Inner cable mounting nut (A) on the bell crank. Pass the inner cable through the cable adjustment barrel (A) along the groove NOTICE in the link and between the link and Make sure to pass the inner cable through the 2 inner cable mounting plate (C). groove in the link. (B) (C) (D)

Set the REVOSHIFT lever to 2.

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With the inner cable kept tight, tighten the inner cable mounting nut while positioning the end of the link between the two white lines on the window.

(y) White lines (z) Position the end of the link between the white lines.

(y) (y)

(z)

After tightening the inner cable mounting nut, cut off the excess length of inner cable.

(z) Within 4 mm 5

(z)

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Tighten the bottom cover (B) with the (A) Bottom cover fixing screw (A) bottom cover fixing screw (A). (B) Bottom cover

Tightening torque 0.4 - 0.7 N·m (SM-BC03) (B) 0.35 - 0.55 N·m 6 (SM-BC04/SM-BC06)

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Installation of the sprocket to the hub (SM-GEAR)

Place the right-hand waterproof cap B (A) Snap ring (A) (C) onto the driver (D) on the right side (B) Sprocket of the hub body. (C) Right-hand waterproof cap B Next, install the sprocket (B) and secure (D) Driver (B) it in place with the snap ring (A). (E) Right-hand waterproof cap A

(z) Note the direction (z) (C)

(D) (E)

Installation of the sprocket to the hub (CS-S500 sprocket with chain guard)

Install the chain guard (B) to the (A) Right-hand waterproof cap B (z) right-hand waterproof cap A (D) of the (B) Chain guard (A) hub body, and then install the right- (C) Driver hand waterproof cap B (A) to the driver (C). (D) Right-hand waterproof cap A

(z) Note the direction (B) NOTICE

Do not use an inward assembling sprocket with 16T or less, otherwise the right-hand waterproof cap A will come into contact with the sprocket.

(A) (B)

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Install the CS-S500 sprocket (C) to the (A) Snap ring (A) driver (D) on the right side of the hub (B) Guard plate body with the guard plate (B) facing (C) CS-S500 Sprocket outward, and secure it in place with the (D) Driver (B) snap ring (A). 2 (C) (D)

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Installation of the hub to the frame (for disc brakes)

Install the disc brake rotor (A) to the (A) Disc brake rotor hub. (B) Disc brake rotor mounting ring (C) TL-LR10 (A) (B) (C)

Tightening torque 1

40 N·m

< When not using the chain tensioner >

Mount the chain on the sprocket, and (A) Dropout then set the hub axle (B) into the (B) Hub axle dropout (A).

2 (A) (B)

< When using the chain tensioner >

Mount the chain on the sprocket, and (A) Chain tensioner then set the hub axle into the dropout.

When using the chain tensioner (A), be sure to read the attached instruction manual for the CT-S500 chain tensioner. 2 (A)

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(A) Place the non-turn washer (A) onto the (A) Non-turn washer left side of the hub axle from the outer (z) side. NOTICE

At this time, turn the hub axle and install Use a non-turn washer that matches the the non-turn washer so that the shape of the dropout. protrusion of the washer fits into the Non-turn washer (for left side use) groove in the dropout. Dropout Mark / Color Size ϴ ≤ 20° Standard (z) The protrusion should be on the ϴ ≤ 38° 3 dropout side. Reversed 2 / Yellow ϴ = 0° Reversed (full chain ϴ = 0° Install the non-turn washer so case) Vertical 8L / Green = 60° - 90° that the protrusion fits securely in ϴ the dropout groove at the front and back sides of the hub axle. Mark

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Take up the slack in the chain and secure (A) Washer (3.2 mm) the wheel to the frame, using a 3.2 mm (B) Hub nut (9 mm) washer (A) and a 9 mm hub nut (B) on the right side and a cap nut on the left side of the hub axle. Tightening torque

30 - 45 N·m

NOTICE (B) (A) Make sure that the hub axle on the right side protrudes about 8 to 13 mm from the end face of the hub nut. Sprocket Dropout Washer (3.2 mm) 8 - 13 mm

Hub axle 4 Hub nut (9 mm)

Total width of the dropout and chain tensioner: 6.5 to 10 mm

When installing the hub to the frame, the chain guard may come off, so check that the chain guard is securely installed so that it will not come off. If installation is incomplete, noise may be generated.

Chain guard

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Installation of the hub to the frame (for roller brakes)

(z) Engage the serrations on the hub body (A) Inter-M brake (B) with the serrations on the inter-M (B) Hub body brake (A), and then provisionally tighten the brake unit fixing nut. NOTICE (z) Align the serrations Fully tightening the brake unit fixing nut may 1 make the wheel difficult to turn when the arm clip is attached later. Refer to the instruction manual for the inter-M brake for details on installing the (A) (B) inter-M brake.

Mount the chain on the sprocket, and (A) Hub axle then set the hub axle (A) into the (B) Dropout dropout (B).

(A) 2 (B)

(A) (z) Place the non-turn washer (A) onto the (A) Non-turn washer (gold) left side of the hub axle from the outer side. NOTICE

At this time, turn the hub axle and install ••When installing a stand to the hub axle, the non-turn washer so that the place the non-turn washer onto the stand protrusion of the washer fits into the from the outer side so that the protrusion groove in the dropout. fits into the groove in the stand. ••When installing a part such as a mudguard (z) The protrusion should be on the stay to the hub axle, place it onto the outer dropout side. side of the non-turn washer.

3 Install the non-turn washer so Stand that the protrusion fits securely in the dropout groove at the front and back sides of the hub axle.

Non-turn washer Mudguard stay Carrier stay

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Install the brake arm (C) of the inter-M (A) Chainstay brake to the chainstay (A) using the arm (B) Arm clip clip (B) and temporarily tighten the clip (C) Brake arm bolt and clip nut loosely. (A)(B) (D) (D) Brake unit fixing nut Then, tighten the brake unit fixing nut (D). Tightening torque 4 20 - 25 N·m

NOTICE

If it is impossible to temporarily attach the (C) brake arm to the chainstay due to misalignment of the brake arm as shown in the illustration, loosen the brake unit fixing nut and turn the brake arm before temporarily attaching it to the chainstay. Then, tighten the brake unit fixing nut.

< For a 170.3 mm long axle >

Take up the slack in the chain and secure (A) Flange nut the wheel to the frame with the flange nut (A). Tightening torque

30 - 45 N·m

NOTICE

Make sure that the hub axle on the right side (A) protrudes 8 to 13 mm from the end face of 5 the flange nut. Sprocket Dropout

8 - 13 mm

Hub axle Flange nut (11 mm)

Total width of the dropout and chain tensioner: 4 to 7.5 mm

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< For a 189.4 mm long axle >

If the total width of the dropout and (A) Chain tensioner other parts such the stand and (B) Mudguard stay mudguard stay (B), on the right side of (A) (B) (C) Washer (3.2 mm) the hub axle, is 8.5 to 11.5 mm (D) Hub nut (9 mm) Secure the right side of the hub axle (E) Carrier stay with two 3.2 mm washers (C) and a 9 mm (F) Stand hub nut (D). (G) Washer (2 mm) Secure the left side of the hub axle with (H) Hub nut (7 mm) a 3.2 mm washer and a 9 mm hub nut. Tightening torque (C) (C) (D) Example: Mount the parts in the order shown in the illustration. 30 - 45 N·m If the total width of the dropout and other parts such the stand and (A) (B) (E) mudguard stay, on the right side of the NOTICE hub axle, is 11.5 to 14.5 mm In any of the cases described in this step, Secure the both side of the hub axle with make sure that the hub axle on the right side a 3.2 mm washer (C) and a 9 mm hub nut protrudes 8 to 13 mm from the end face of 5 (D). the hub nut.

Example: Mount the parts in the order shown in the illustration.

If the total width of the dropout and (F) other parts such the stand (F) and mudguard stay, on the right side of the hub axle, is 14.5 to 17 mm

Secure both sides of the hub axle with a (A) 2 mm washer (G) and a 7 mm hub nut (H). (E) Example: Mount the parts in the order shown in the illustration.

(G)(B) (H)

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Fix the brake arm (C) of the inter-M (A) Chainstay brake securely to the chainstay (A) with (B) Arm clip the arm clip (B). (C) Brake arm (A) (B) (z) If excessive force is applied to the brake arm, the wheel will become Tightening torque difficult to turn. (C) Be careful not to apply excessive 2 - 3 N·m force when installing. (z) NOTICE

••When installing the arm clip, securely 6 tighten the clip bolt while holding the clip nut with a 10 mm spanner. ••After installing the arm clip, check that the clip bolt protrudes about 4 mm from the end face of the clip nut.

Clip nut Brake arm

Arm clip

Clip bolt (M6 × 16 mm)

About 4 mm

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Installing the brake cable

Place the cable adjustment barrel (A) so (A) Cable adjustment barrel (A) (B) that it is 15 – 17 mm from the end of the (B) Brake arm brake arm (B), and then pass the inner (C) Hole in the inner cable fixing bolt cable through the cable adjustment barrel of the brake arm and then through the hole in the inner cable fixing bolt (C).

(z) Should be 15 – 17 mm 1 (z)

(C)

Check that both ends of the outer casing (A) Cable adjustment barrel (z) are securely inserted into the cable adjustment barrels (A) of both the brake lever and brake arm.

(z) Both ends of the outer casing 2 should be securely inserted.

(A)

Pull the link (A) back until it stops. Then, (A) Link while pulling the inner cable (C) to apply (B) Inner cable fixing nut the full amount of tension to the cable, (C) Inner cable tighten the inner cable fixing nut (B). (A) Tightening torque

3 (C) 6 - 8 N·m

(B) NOTICE

Set the inner cable so that it passes below the link as shown in illustration (z). (z)

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Adjusting the brake cable

After checking that the wheel does not NOTICE easily turn while the brake cable is being If the brake cable is not run in, it will need to pulled, depress the brake lever about 10 be adjusted again after only a short period of (z) times as far as the grip in order to run in use. 1 the brake cable.

(z) Depress about 10 times

(z) Turn the cable adjustment barrel (A) so (A) Cable adjustment barrel that there is about 15 mm of gap (z) in the brake lever. * The amount of brake lever gap is the distance from the position where the brake lever is not operated to the position where a force is felt suddenly 2 when the brake lever is pulled.

(A)

After depressing the brake lever to check (A) Cable adjusting nut the braking performance, secure the cable adjustment barrel with the cable adjusting nut (A). Tightening torque

3 1 - 2 N·m

(A)

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Installation of the hub to the frame (for coaster brakes)

Mount the chain on the sprocket, and (A) Hub axle then set the hub axle (A) into the (B) Dropout dropout (B).

(A) 1 (B)

(A) (z) Place the non-turn washer (A) onto the (A) Non-turn washer (yellow) left side of the hub axle from the outer side.

At this time, turn the hub axle and install the non-turn washer so that the protrusion of the washer fits into the 2 groove in the dropout. (z) The protrusion should be on the dropout side.

Install the non-turn washer so that the protrusion fits securely in the dropout groove at the front and back sides of the hub axle.

(A) (B)(C) Install the brake arm (A) to the chainstay (A) Brake arm (D) using the arm clip (E) and temporarily (B) Clip nut tighten the clip bolt (C) and clip nut (B) (C) Clip bolt loosely. (D) Chainstay 3 Then, tighten the brake unit fixing nut. (E) Arm clip (D) (E)

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Take up the slack in the chain and secure (A) Flange nut the wheel to the frame with the flange nut (A). Tightening torque

30 - 45 N·m

NOTICE

(A) Make sure that the hub axle on the right side protrudes 8 to 12.5 mm from the end face of the flange nut. 4 Sprocket Dropout 8 - 12.5 mm

Hub axle Flange nut

Total width of the dropout and other parts such the stand and mudguard stay: 4 to 7.5 mm (Axle length: 168 mm / 175 mm) 9 to 12.5 mm (Axle length: 178 mm)

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(A) (B) (C) Fix the brake arm (A) securely to the (A) Brake arm chainstay (D) with the arm clip (E). (B) Clip nut (C) Clip bolt (D) Chainstay (E) Arm clip

(D) (E) Tightening torque

2 - 3 N·m

NOTICE 5 ••When installing the arm clip, securely tighten the clip bolt while holding the clip nut with a 10 mm spanner. ••After installing the arm clip, check that the clip bolt protrudes about 2 to 3 mm from the end face of the clip nut.

Clip nut Brake arm

Arm clip

Clip bolt (M6 × 16 mm)

About 2 to 3 mm

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Installation of the bell crank

Insert the push rod (A) into the hub axle. (A) Push rod

(z) About 14 mm

The push rod should protrude about 14 mm from the end face 1 of the hub axle.

(A)

(z)

While pushing the bell crank into the (A) Bell crank fixing bolt hub axle, align the serrations inside the (B) 5 mm hexagon wrench or 10 mm bell crank with the hub nut (C), and spanner continue push until the crank comes into (C) Hub nut contact with the end face (E) of the hub axle. (D) Edge of the window (E) End face of the hub axle While keeping the parts in this position, tighten the bell crank fixing bolt (A) onto the hub axle. Tightening torque (A) (B) Make sure that the edge (D) of the 2 window is aligned with the end face of the hub axle. 3 - 5 N·m

Securing the shifting cable to the frame

Secure the cable to the frame with the (A) Outer casing bands outer casing bands (A).

(z) (y) (y) 20 - 25 cm (z) Slacken the cable to prevent strain from being placed on the cable when turning the handlebars.

(A)

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ADJUSTMENT

For bell cranks

Set the REVOSHIFT lever to 2. (A) Cable adjustment barrel (B) Push rod Next, turn the cable adjustment barrel (C) End of the hub (A) to align the red line (D) on the push rod with the end (C) of the hub axle. (D) Red line on the push rod (E) Yellow lines (F) Yellow part of the link

NOTICE

(A) During adjustment, check the two yellow lines through the window from above. 1

(B)

While turning the crank, move the REVOSHIFT lever from 3 to 1 then back to 3. Repeat this two or three times and check to see that the gears are being shifted. Move the REVOSHIFT 2 lever from 1 to 2 again and make sure that the red line on the push rod is aligned with the end of the hub axle. If they are not aligned, perform readjustment.

After adjusting the bell crank IV, fix the (A) Cable adjustment nut cable adjustment barrel with the cable adjustment nut (A). Tightening torque (A) 1.5 - 2.5 N·m

3 SET

SET

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MAINTENANCE

Replacement of the shifting cable

REVOSHIFT lever (In the case of 3S41-E/3S42-E)

Set the REVOSHIFT lever to 1. TECH TIPS (z) Set to 1 Use a shifting cable with one inner cable drum. * The shape differs depending on the model. 1 Cassette joint Shifting lever side side

(z) Plastic cap Plastic cap

Loosen the two cover fixing screws (A) (A) Cover fixing screw and remove the cover (B). (B) Cover

(A) 2 (A) (B)

(A) (B)(C) Pass the inner cable from the hole in the (A) Hole in outer casing holder winder unit (C) through the hole in the (B) Groove of cable guide 2 outer casing holder (A). 3 (C) Hole in winder unit Next, insert the inner cable into the 3 groove of the cable guide (B).

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Pull the inner cable so that the inner (A) Recess in winder unit cable drum fits into the recess in the winder unit (A). 4

(A)

(A) Insert the outer casing into the outer (A) Outer casing holder casing holder (A). 5

Fasten the cover (B) with the 2 cover (A) Cover fixing screw (A) (B) fixing screws (A). (B) Cover

Tightening torque 6 0.1 - 0.2 N·m

(A)

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REVOSHIFT lever (In the case of 3S35-E)

(z) Set the REVOSHIFT lever to 1. TECH TIPS (z) Set to 1 Use a shifting cable with one inner cable drum. * The shape differs depending on the model. 1 Cassette joint Shifting lever side side

Plastic cap Plastic cap

(A) Loosen the cover fixing screw (A), and (A) Cover fixing screw then remove the indicator cover (B). (B) Indicator cover

(B) 2

Set the inner cable onto the pulley. (A) Hole in outer casing holder (B) (B) Groove in pulley Insert the inner cable into groove (B) (C) Projection on pulley (C) from the inside of the projection on the pulley (C), and then pass it through the hole in the outer casing holder (A). NOTICE

Check that the inner cable is correctly routed 3 along the inside of the projection on the pulley.

(A)

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Hook the inner cable into groove in the (A) Groove in pulley pulley (A), and pull the inner cable so (B) Outer casing holder that the inner cable drum fits into the (C) Hole in pulley 1 hole in the pulley (C).

(A) After this, insert the outer casing into the outer casing holder (B). 4 3

(B) (C)

5 Replace the indicator cover and tighten the cover fixing screw.

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Oil maintenance of the internal assembly

To maintain the product in good working order, it is recommended to have a bicycle dealer or (A) WB maintenance oil set nearest agency carry out maintenance such as lubrication of the internal parts about once every (Y00298010) two years from the first time of use (once about every 5,000 km if the bicycle is used very frequently). Also, for carrying out maintenance, the use of Shimano internal geared hub grease or a lubrication kit is recommended. If Shimano grease or a Shimano lubrication kit is not used, problems such as a malfunction in gear shifting may occur.

(A)

Fill the bottle with maintenance oil to a height of 95 mm.

(z) 95 mm 1

(z)

Immerse the internal unit into the oil (z) from the left side until the oil reaches up to ring gear unit 1, as shown in the illustration. 2 (z) Ring gear unit 1

Keep the internal unit immersed for approximately 90 seconds.

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Remove the internal unit from the oil.

Let the excess oil drain off for approximately 60 seconds.

After lubrication is complete, reassemble TECH TIPS the hub.

••Maintenance oil is reusable. Refill it as needed. 6 ••Store it with the lid closed after use.

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Troubleshooting

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loe ie n rts list Troubleshootingnter hub troubleshooting

ioer Roer rae pto aue and reed R nter u RR nter rae eani pin or xe engt ree or ip reae en in top nterna e nterna ae

R gear or xe engt e ran or xe engt xe unit rier unit

eani pin or xe engt ree or ip Ring gear unit en in nora gear

R rier unit 13 1 1 eani pin 1 ree or ip 2 en in o 3 gear R 32 1 13 arrier unit 1 1 R 32 32 1 32 1 R R 13 1 1 1 11 13 1 a retainer nterna u greae 1 12 1 2 1 13 32 1 1 2 32 1 32 1 1 2 2 13 1 1 1 1 1 1 111 3 1 Rigt and dut ap 1 2 21 22 23 1 2 R 2 R 1 ear iting i e ran unit 1 not poie 1 2 2 21 22 23 2 R 1 13 2 1 1 u rod doe 2 3 not oe 31 32 u rod 33 1 3 1 32 1 11 Return to index page

Disassembly and Assembly

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Tools

a: TL-HS20 Hub spanners Part no. Y-320 90010 15 mm/17 mm (2 pcs.) b: TL-HS10 Hub spanners Part no. Y-230 90010 13 mm x 14 mm (2 pcs.) c: Slotted Screwdriver

a b c

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Disassembly of the INTER-3 Hub (Roller Brake Spec.)

1. Hold the two beveled surfaces of the hub axle in a vise.

Vise NOTICE

••Do not damage the threads of the hub axle.

2. Remove the right hand dust cap A Right hand with a slotted screwdriver. dust cap A

Slotted screwdriver

3. Hold the two beveled surfaces of the hub axle on the driver side in a vise.

NOTICE Driver ••Do not damage the threads of the hub axle.

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Disassembly of the Inter-3 hub

4. Hold the left hand cone, and then TL-HS10(14 mm) remove the lock nut for left hand cone. Next, remove the left hand cone. Lock nut for left hand cone

TL-HS10(14 mm)

Left hand cone

5. Remove the hub shell.

Hub shell

Now it can be replaced with the Internal assembly for quick replacement new internal assembly. Part no. Axle length Y-33S 90700 170.3 mm Y-33S 98270 176.8 mm Y-33S 90710 189.4 mm

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Disassembly of the Inter-3 hub

6. Remove the stop ring with a slotted screwdriver Slotted screwdriver At this time, the stop ring come off with great force. Be careful of the safety using cloth and so on.

Stop ring (9.6 mm dia.)

7. Remove the carrier unit and the ring gear unit at the same time while turning the ring gear unit Carrier unit slightly to the left and right.

Carrier unit

Ring gear unit Ring gea unit

After removing them at the same time, remove the carrier unit from the ring gear unit.

8. Remove ball retainer K while pressing in pawl A-1 and pawl A-2 on the driver unit with your fingers. Pawl A-1

Pawl A-2

Ball retainer K

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Disassembly of the Inter-3 hub

9. Turn the axle unit with driver upside down and hold the two Axle unit with driver beveled surfaces of the axle in a vise.

NOTICE

••Do not damage the threads of the hub axle.

10. Remove the right hand lock nut and the right hand cone with dust seal from the hub axle.

TL-HS20 Right hand lock nut (17 mm)

TL-HS20 (15 mm)

Right hand cone with dust seal

11. Remove ball retainer J from the driver unit.

Ball retainer J

Driver unit

38 Return to index page

Disassembly of the Inter-3 hub

12. Turn the driver unit clockwise to remove it from the axle unit. Turn the driver unit clockwise

Driver unit

NOTICE

••Do not disassemble the axle unit, otherwise it may cause problems with gear shifting.

This completes the disassembly of the Inter-3 hub.

39 Return to index page

Assembly of the INTER-3 Hub (Roller Brake Spec.)

1. Hold the two beveled surfaces of the axle unit on the gear side in a vise.

Gear

Axle unit Vise NOTICE

••Do not damage the threads of the hub axle.

Smaller indents inside 2. Install the driver unit onto the the driver unit axle unit.

Driver unit

Smaller projections at top of clutch Clutch NOTICE

Axle unit ••Align the two smaller indents inside the driver unit with the two smaller projections at the top of the clutch when installing the driver unit.

3. Place ball retainer J onto the driver unit

Ball retainer J NOTICE

Driver unit ••Be careful of the setting direction. ••Apply a liberal coating of internal hub grease.

(Y04120800)

40 Return to index page

Assembly of the Inter-3 hub

4. Screw the right hand cone with dust seal onto the hub axle as far as it will go. Right hand lock nut Then turn the right hand cone counterclockwise by 120 degree, and then secure it by tightening the right hand lock nut.

Right hand cone with dust seal

120º

TL-HS20 (17 mm) TL-HS20 (15 mm)

Tightening torque: 12 - 20 N·m {104 - 174 in.lbs}

5. Turn the axle unit with driver upside down and hold the two beveled surfaces of the axle on the driver side in a vise.

Axle unit with driver

NOTICE

••Do not damage the threads of the hub axle.

41 Return to index page

Assembly of the Inter-3 hub

6. Install ball retainer K while pressing in pawl A-1 and pawl A-2 on the driver unit with your Fingers.

Pawl A-1 NOTICE Ball retainer K ••Be careful of the setting direction. ••Apply a liberal coating of internal Pawl A-2 hub grease.

(Y04120800)

7. While pushing the two pawls B Ring gear unit NOTICE on the ring gear unit with your fingers, push the two pawls A-1 ••Be careful of the directions of the two pawls B. and the two pawls A-2 on the Pawl B ••Apply a liberal coating of internal hub driver unit one by one with a grease. slotted screwdriver and install the Internal ••Check that pawls B are not hooked ring gear unit to the driver unit. Pawl A-2 ratchet onto the clutch. Pawl A-1 mechanism Slotted ••Check that pawls A-1 and A-2 care screwdriver engaged with the ratchet mechanism Driver unit in the ring gear unit. ••Apply a liberal coating of internal hub grease to the gear inside the ring gear unit.

OK Not O K

42 Return to index page

Assembly of the Inter-3 hub

8. Engage the teeth of the planetary gear of the carrier unit with the teeth of the ring gear unit while turning the carrier unit slightly to the left and right and pushing it onto the ring gear unit. Check

Teeth of ••Check that the stop ring groove of carrier unit the hub axle is visible from the edge planetary gear Teeth of ring of the carrier unit after the carrier gear unit unit has been installed.

NOTICE

••Apply a liberal coating of internal hub grease to the planetary gear (in 4 places) inside the carrier unit.

9. Insert the stop ring into the NOTICE groove of the hub axle. ••After inserting the stop ring, check Carrier unit that there is a small amount of play in the carrier unit in the vertical direction. If there is no vertical play and the carrier unit turns stiffly, turn the internal assembly upside down and hold the hub axle in a vice. Then loosen the right hand lock nut and the right hand cone with dust seal to adjust until there is sufficient play. Stop ring Groove of hub (9.6 mm dia.) axle

10. While turning the hub shell Hub shell counterclockwise slightly, place it onto the internal assembly.

Internal assembly

43 Return to index page

Assembly of the Inter-3 hub

11. Screw on the left hand cone to TL-HS10(14 mm) adjust so that the hub shell can be turned smoothly without any play. After adjusting, secure the left hand cone with the lock nut Lock nut for left hand cone for left hand cone.

TL-HS10(14 mm)

Tightening torque: 12 - 20 N·m {104 - 174 in.lbs} Left hand cone

12. Turn the hub upside down and hold the two beveled surfaces of the axle in a vise. Driver

NOTICE

••Do not damage the threads of the hub axle.

Install right hand dust cap A to 13. Right-hand lock nut Check the hub shell. ••After installing right hand dust cap A to the hub shell, turn the hub shell clockwise and check that it turns smoothly. If the hub shell does not turn smoothly, re-install right hand dust cap A.

NOTICE

••Apply a coating of internal hub grease to the inside of right hand dust cap A to waterproof it. ••Push right hand dust cap A firmly onto the hub shell until it clicks. This completes the assembly of the Inter-3 hub

44 Return to index page

Service Parts

45 Return to index page

Service Parts

Bell Crank

No image

SM-BC03 SM-BC04 SM-BC06

Non-Turn Washer The shape of the dropout determines which NTW to choose. In the illustration below, you can see the result for various frame dropouts in combination with the chosen NTW .

Non-Turn Washer (for left side use) Dropout Mark / Color Size Mark Except vertical type 2 / Yellow =0° 60°

Vertical type 8L / Green =60° 90

46 Return to index page

Interchangeability

47 Return to index page

Interchangeability

Compatible Products

SG-3R40 SG-3R40

Internal Unit SG-3C41 SG-3C41

SG-3D55 SG-3D55

(NOTE) *The specifications differ depending on the length of the axle etc. Therefore, follow the compatibility of the axle length and such.

48 Return to index page

Hub dimensions (Over Locknut Dimensions and Axle)

49 Return to index page

Hub dimensions (Over Locknut Dimensions and Axle)

SG-3R40NEXU / SG-3C41S INTER / SG-D55-3 C-275

12 Series NEXUS ModelSeries No. SG-3R40 NEXUS SG-3C41 SG-3D55 Model No. SG-3R40 SG-3C41 SG-3D55 SG-3R75-B Speed 3 Speed 3 GearGear ratio: ratio: Total Total 186% 186% 158% SalesSales area area AllAll Brake type Hub roller brake Coaster brake Disc brake Brake type Hub roller brake Coaster brake Disc brake Hub roller Hub shell material Steel brakeAluminum Hub shell material Steel Aluminum Steel Spoke size #13 / #14 Spoke size #13 / #14 A AOver Over locknut locknut dim. dim. / O.L.D. / O.L.D. (mm) (mm) 120120 127127 130130 120 127120 135127 122 135 B B AxleAxle length length (mm) (mm) 170170 189 189 177 177 183 183 183.5 183.5 168 178 168 175 178 193 175 174.0 193 PushPush rod rod length length (mm) (mm) 81.8581.85 90.75 90.75 86.85 86.85 90.75 90.75 86.85 81.85 86.85 81.85 86.85 90.7586.85 - 90.75 C C FlangeFlange distance distance (mm) (mm) 53 53 57.5 57.5 53.5 51.1 53.5 D Spoke hole P.C.D. (mm) 74 59 65 83.5 D Spoke hole P.C.D. (mm) 74 59 65 Butterfly spoke hole - E ButterflyFlange diameterspoke hole (mm) 84 - 67.5 77.6 92.5 E FlangeFlange diameterwidth (mm): (mm) F1 (left) 84 2.3 67.5 3.2 2.7 77.6 F FlangeFlange width width (mm): (mm): F1 (left) F2 (right) 2.3 2.3 3.2 2.3 3.2 F Flange width (mm): F215T (right) (flat gear) use 42.2 40.5 45.52.3 43.7 42.2 44.5 - 3.2 G Chain line (mm) Inward assembly 39.7 38 43 41.2 39.7 42 - 15T (flat gear) use 42.2 40.5 45.5 43.7 42.2 44.5 Outward assembly 44.7 43 48 46.2 44.7 47 43.9 G Chain line (mm) Inward assembly 39.7 38 43 41.2 39.7 42 H Offset (mm) 0.8 2.5 1.2 2.7 1.7 3.6 J Axle length from Outward hub (left) assembly 22.544.7 32.7 22.5 24.543 22.5 2148 2646.2 21 26.244.7 26 47 H K Axle lengthOffset (mm) from hub (right) 27.40.8 36.3 27.5 31.42.5 30.8 27 32 26.61.2 31.42.7 26 1.7 J Axle length from hub (left) 22.5 32.7 22.5 24.5 22.5 21 26 21BC3 / 8 TPI26.2 L Axle size BC3 / 8 TPI 26 26 K Axle length from hub (right) 27.4 36.3 27.5 31.4 30.8 27 32 26.6 31.4 Rear dropout mounting width (left, includes L N Axlestay size etc.) BC3 / 8 TPI 26 4.0 - 8.5 - 4.0 - 8.0 - 7.5 - 4.0 - 9.0 - 4.0 - 6.5 - 10.0 4.0 - 9.0 N Rear dropoutRear dropout mounting mounting width (left, width includes (right, stay includes etc.) 7.5 17.0 7.5 11.5 11.0 7.5 12.5 7.5 P stay etc.) 4.0 -7.5 8.5 -17.0 4.0 -7.5 8.0 -11.5 7.5 -11.0 4.0 -7.5 9.0 -12.5 4.0 -7.5 6.5 - 10.0 P Rear dropout mounting width (right, includes stay etc.) Q Non-turn washer width 4.0 4.0 4.0 or 6.4 6.4 Q Non-turn washer width 4.0 4.0 4.0 or 6.4 R Spoke hole diameter (mm) 2.7 2.9 Left: 2.7 R Spoke hole diameter (mm) 2.7 Right: 2.82.9 S S SpokeSpoke hole hole chamfer chamfer 105° 105° 90° 105° 90°

Ver. 2.4, Apr. 9, 2019, SHIMANO INC. Return to index page

EV / Spare Parts List

51 Return to index page

Spare parts list

NEXUS 3-SPEED HUB w/Hi-Power Roller Brake SG-3R40 inter -3 Hub / BR-IM31-R inter -M Brake

34 Grease

18 16 For Axle Length 1 189.4 mm MIN.2Nm 24 25 35 JAPAN 20 21 22 23 Internal Assembly

12 13 14 15 GREASE 2

For Axle Length 29 29 170.3 mm / 176.8 mm SM-BC06 Bell Crank 3 11 26 For Axle Length 30 189.4 mm 30 19 27

13 12 28 T 1 SE SET 31 31 2 3 4 5 6 7 8 9 10 For Axle Length 170.3 mm / 176.8 mm 32 32 11 33 33

ITEM NO. SHIMANO CODE NO. DESCRIPTION ITEM NO. SHIMANO CODE NO. DESCRIPTION Y33S90700 Internal Assembly (Axle Length 170.3 mm) 19 Y75Y98060 Inner Cable Fixing Bolt & Nut 1 Y33S98270 Internal Assembly (Axle Length 176.8 mm) 20 Y31Z06020 Lock Nut for Left Hand Cone Y33S90710 Internal Assembly (Axle Length 189.4 mm) 21 Y33M37000 Left Hand Cone 2 Y33Y19000 Stop Ring (φ9.6 mm) 22 Y31Z07000 Left Hand Dust Cap 3 Y33S90400 Carrier Unit 23 Y32190220 Ball Retainer A (1/4" x 7) 4 Y33S90300 Ring Gear Unit 24 Y33R05000 Right Hand Dust Cap A 5 Y33R90220 Ball Retainer K (7/32" x 10) 25 Y33R52001 Right Hand Dust Cap B Y33S98040 Axle Unit (Axle Length 170.3 mm) Y32203200 Sprocket Wheel 16T (Black) 6 Y33S98280 Axle Unit (Axle Length 176.8 mm) Y73T21830 Sprocket Wheel 18T (Black) Y33S98050 Axle Unit (Axle Length 189.4 mm) Y73T21930 Sprocket Wheel 19T (Black) 7 Y33S90200 Driver Unit 26 Y73T22030 Sprocket Wheel 20T (Black) 8 Y33R90210 Ball Retainer J (7/32" x 8) Y73T22130 Sprocket Wheel 21T (Black) 9 Y33R90500 Right Hand Cone w/Dust Seal Y73T22230 Sprocket Wheel 22T (Black) Y33R08100 Right Hand Lock Nut (5 mm) for Axle Length 170.3 mm / 189.4 mm Y73T22330 Sprocket Wheel 23T (Black) 10 Y32530100 Right Hand Lock Nut (9.9 mm) for Axle Length 176.8 mm 27 Y32120100 Snap Ring C 11 Y22015010 Flange Nut for Axle Length 170.3 mm / 176.8 mm Y33R98080 Push Rod (81.85 mm) for Axle Length 170.3 mm Y32170020 Hub Nut (7 mm) for Axle Length 189.4 mm 28 Y33S98180 Push Rod (86.85 mm) for Axle Length 176.8 mm 12 Y20003000 Hub Nut (9 mm) for Axle Length 189.4 mm Y33S98290 Push Rod (90.75 mm) for Axle Length 189.4 m Y22006000 Washer (2 mm) for Axle Length 189.4 mm Y6P198030 SM-BC06 Bell Crank Unit 13 29 Y22006040 Washer (3.2 mm) for Axle Length 189.4 mm Y33S95100 Bell Crank 3 Unit 14 Y33Z20200 Non-turn Washer 2 (Yellow) 30 Y33S98010 Cable Adjusting Bolt & Nut Y75V13000 Brake Unit Fixing Nut (8.2 mm) for Axle Length 170.3 mm / 189.4 mm Y33S74000 Bell Crank Body Fixing Bolt for SM-BC06 15 31 Y75V13010 Brake Unit Fixing Nut (9.7 mm) for Axle Length 176.8 mm Y33S57000 Bell Crank Body Fixing Bolt for Bell Crank 3 16 Y75F11000 Grease Hole Cap 32 Y33S98030 Inner Cable Fixing Bolt Unit Y75M98050 Brake Arm Clip Unit (φ15 mm) Y6P198040 Bell Crank Cover & Fixing Screw for SM-BC06 33 Y33F98090 Brake Arm Clip Unit (5/8") Y33S98020 Bell Crank Cover & Fixing Screw for Bell Crank 3 17 Y75M98060 Brake Arm Clip Unit (11/16") Y04120800 Internal Hub Grease (Net. 100g) 34 Y33F98100 Brake Arm Clip Unit (3/4") Y04120400 Roller Brake Grease (Net. 100g) 18 Y75Y98050 Brake Cable Adjusting Bolt & Nut 35 Y04140020 Roller Brake Grease (Net. 10g)

52 Return to index page

Spare parts list

NEXUS 3-SPEED HUB w/CoasterNEXUS Brake 3-SPEED HUB w/Coaster Brake Inter-3 Hub SG-3C41 inter -3 Hub / LeftSG-3C41 Side Non-turn Left Washer Side Non-turn Spec. Washer Spec.

17 31 18 19 Internal Hub Grease 1 21 22 23 24 (For coaster brake also) 16 20 Internal Assembly

26 26

12 13 14 15 SM-BC06 Bell Crank 3 27 27 1

12 25 SET

2 3 4 5 6 7 8 9 10 11 SET 28 28

29 30 30 29

ITEM SHIMANO DESCRIPTION NO. CODE NO. Y35U98010 Internal Assembly (Axle Length 168 mm) 1 Y33R98020 Internal Assembly (Axle Length 175 mm) ITEM NO. SHIMANO Y35U98020CODE NO. DESCRIPTIONInternal Assembly (Axle Length 178 mm) ITEM NO. SHIMANO CODE NO. DESCRIPTION 2Y35U98010Y33R90600 InternalBrake Assembly Shoe (Axle Unit Length 168 mm) 18 Y75M06000 Clip Screw (M6 x 16) Stop Ring (ø9 mm) 1 3Y33R98020Y32532000 Internal Assembly (Axle Length 175 mm) 19 Y31727200 Clip Nut 4 Y33R90700 Carrier Unit Y35U98020 Internal Assembly (Axle Length 178 mm) 20 Y33R90200 Ball Retainer L (3/16" x 14) 5 Y33R90800 Ring Gear Unit 2 * 6Y33R90600Y35U98060 Brake ShoeBall UnitRetainer K (7/32" x 11) 21 Y33R05000 Right Hand Dust Cap A 3 Y32532000Y33R98050 Stop RingAxle (ø9 Unit mm) (Axle Length 168 mm) 22 Y33R52001 Right Hand Dust Cap B 4 7Y33R90700Y33R98040 Carrier UnitAxle Unit (Axle Length 175 mm) Y32203200 Sprocket Wheel 16T (Black) Y35U98030 Axle Unit (Axle Length 178 mm) 5 Y33R90800 Ring Gear Unit Y73T21830 Sprocket Wheel 18T (Black) 8 Y33R90400 Driver Unit 6 * 9Y35U98060Y35U98070 Ball RetainerBall Retainer K (7/32" x J 11) (7/32" x 8) Y73T21930 Sprocket Wheel 19T (Black) 10Y33R98050Y33R90500 Axle UnitRight (Axle Hand Length Cone 168 mm)w/Dust Seal 23 Y73T22030 Sprocket Wheel 20T (Black) Y32139040 Right Hand Lock Nut (4.5 mm) for Axle Length 168 mm/178 mm 7 11Y33R98040 Axle Unit (Axle Length 175 mm) Y73T22130 Sprocket Wheel 21T (Black) Y32530100 Right Hand Lock Nut (9.9 mm) for Axle Length 175 mm Y35U98030 Axle Unit (Axle Length 178 mm) Y73T22230 Sprocket Wheel 22T (Black) 12 Y22015010 Flange Nut 8 13Y33R90400Y33Z20200 Driver UnitNon-turn Washer 2 (Yellow) Y73T22330 Sprocket Wheel 23T (Black) 9 Y35U98070Y33R49010 Right HandLeft ConeHand w/Dust Lock SealNut (3 mm) for Axle Length 168 mm/17824 mm Y32120100 Snap Ring C 14 10 Y33R90500Y33R49020Right HandLeft Lock Hand Nut (5 mm)Lock for Nut Axle (5Length mm) 170.3 for mm Axle / 189.4 Length mm 175 mm Y33R98080 Push Rod (81.85 mm) for Axle Length 168 mm 15 Y33R48010 Stop Nut (3 mm) 25 Y32139040 Right Hand Lock Nut (4.5 mm) for Axle Length 168 mm/178 mm Y33S98180 Push Rod (86.85 mm) for Axle Length 175 mm/178 mm 11 16 Y35U98040 Brake Arm Unit Y32530100Y33F98090 Right HandBrake Lock Arm Nut Clip (9.9 mm)Unit for(5/8") Axle Length 175 mm Y6P198030 SM-BC06 Bell Crank Unit 17 26 12 Y32170020Y33F98100 Flange NutBrake Arm Clip Unit (3/4") Y33S95100 Bell Crank 3 Unit 13 18Y33Z20200Y75M06000 Non-turnClip Washer Screw 2 (Yellow) (M6 x 16) 27 Y33S98010 Cable Adjusting Bolt & Nut Clip Nut 19Y33R49010Y31727200Left Hand Lock Nut (3 mm) for Axle Length 168 mm/178 mm Y33S74000 Bell Crank Body Fixing Bolt for SM-BC06 14 20 Y33R90200 Ball Retainer L (3/16" x 14) 28 Y33R49020 Left Hand Lock Nut (5 mm) for Axle Length 175 mm Y33S57000 Bell Crank Body Fixing Bolt for Bell Crank 3 21 Y33R05000 Right Hand Dust Cap A 15 22Y33R48010Y33R52001 Stop NutRight (3 mm) Hand Dust Cap B 29 Y33S98030 Inner Cable Fixing Bolt Unit 16 Y35U98040Y32203200 Brake ArmSprocket Unit Wheel 16T (Black) Y6P198040 Bell Crank Cover & Fixing Screw for SM-BC06 Sprocket Wheel 18T (Black) 30 Y33F98090Y73T21830 Brake Arm Clip Unit (5/8") Y33S98020 Bell Crank Cover & Fixing Screw for Bell Crank 3 17 Y73T21930 Sprocket Wheel 19T (Black) Y33F98100 Brake Arm Clip Unit (3/4") 31 Y04120800 Internal Hub Grease (Net. 100g) 23 Y73T22030 Sprocket Wheel 20T (Black) Y73T22130 Sprocket Wheel 21T (Black) Y73T22230 Sprocket Wheel 22T (Black) Y73T22330 Sprocket Wheel 23T (Black) 24 Y32120010 Snap Ring C Y33R98080 Push Rod (81.85 mm) for Axle Length 168 mm 25 Y33S98180 Push Rod (86.85 mm) for Axle Length 175 mm/178 mm Y6P198030 SM-BC06 Bell Crank Unit 26 Y33S95100 Bell Crank 3 Unit 27 Y33S98010 Cable Adjusting Bolt & Nut Y33S74000 Bell Crank Body Fixing Bolt for SM-BC06 28 Y33S57000 Bell Crank Body Fixing Bolt for Bell Crank 3 29 Y33S98030 Inner Cable Fixing Bolt Unit Y6P198040 Bell Crank Cover & Fixing Screw for SM-BC06 30 Y33S98020 Bell Crank Cover & Fixing Screw for Bell Crank 3 31 Y04120800 Internal Hub Grease (Net. 100g) Apr.-2010-2330B © Shimano Inc. I

Specifications are subject to change without notice. 53 Return to index page

Spare parts list NEXUS 3-Speed Internal Hub SG-3D55 NEXUS 3-Speed Internal Hub SG-3D55

1 19 20 21 22 15 11 12 13 14 17 18 Internal Assembly 16

1 27

SM-BC06 2 3 4 5 6 7 8 9 10 28

23 24 25 26 SET

SET 29

TL-AF30 Internal Hub Grease 32 33 30 31

SG-3R40 SG-3R55 SG-S500 ITEM SHIMANO DESCRIPTION INTERCHANGE- ITEM NO. SHIMANONO. CODECODE NO. NO. DESCRIPTION ITEM NO. SHIMANO CODE NO. DESCRIPTION ABILITY 1 Y-36U1 98010Y-36U 98010 InternalInternal Assembly Assembly (Axle Length (Axle 192.6 Length mm) 192.6 mm) 18 Y-36U 98030 Ball Retainer (7/32" x 9) 2 Y-33Y 19000 Stop Ring ( 9.6 mm) AA 2 Y-33Y 19000 Stop Ring ( 9.6 mm) 19 Y-36U 09000 Right Hand Dust Cap A 3 Y-35E 98020 Carrier Unit A 3 Y-35E4 98020Y-35H 90300 CarrierRing Unit Gear Unit 20 Y-36U 10000 Chain Guard A 4 Y-35H5 90300Y-33R 90220 Ring GearBall Unit Retainer K (7/32" x 10) 21 Y-33R 52001 Right Hand Dust CapAA B 5 Y-33R6 90220Y-36U 98020 Ball RetainerAxle Unit K (7/32" (Axle x Length10) 192.6 mm) Y-1ZN 98010 Sprocket Wheel 18T w/Guard Plate (CS-S500) 22 6 Y-36U7 98020Y-33S 90200 Axle UnitDriver (Axle Unit Length 192.6 mm) Y-1ZN 98020 Sprocket Wheel 20TA w/Guard Plate (CS-S500) 8 Y-33R 90210 Ball Retainer J (7/32" x 8) AA 7 Y-33S 90200 Driver Unit 23 Y-321 20100 Snap Ring C 9 Y-33R 90500 Right Hand Cone w/Dust Seal A 8 10Y-33R 90210Y-325 30120 Ball RetainerRight HandJ (7/32" Lock x 8) Nut (9.9 mm) 24 Y-220 06010 Washer (3.2 mm) B 9 11Y-33R 90500Y-24Z 02000 Right HandRotor Cone Mount w/Dust Cover Seal 25 Y-200 03000 Hub Nut (9 mm) A 10 12Y-325 30120Y-314 14010Right HandCap Lock Nut Nut (3/8") (9.9 mm) 26 Y-33S 98290 Push Rod (90.75 mm) A Y-34R 85000 Non-turn Washer 8L (Dark Green) A 11 13Y-24Z 02000 Rotor Mount Cover 27 Y-6P1 98030 SM-BC06 Bell Crank Unit Y-33Z 20200 Non-turn Washer 2 (Yellow) A 12 Y-314 14010 Cap Nut (3/8") 28 Y-33S 98010 Cable Adjusting Bolt & Nut 14 Y-35Z 19000 Left Hand Serated Lock Nut (10.7 mm) A Y-34R 85000 Non-turn Washer 8L (Dark Green) 29 Y-33S 74000 Bell Crank Body Fixing Bolt 13 15 Y-35Z 98060 Left Hand Cone w/Dust Cap & Seal Ring A 16Y-33Z 20200Y-377 10000 Non-turnSeal Washer Ring 2 (Yellow) 30 Y-33S 98030 Inner Cable Fixing Bolt Unit A 14 17Y-35Z 19000Y-32T 08100Left HandLeft Serrated Hand LockInner Nut Dust (10.7 Cap mm) 31 Y-6P1 98040 Bell Crank Cover & Fixing ScrewA 15 18Y-35Z 98060Y-36U 98030 Left HandBall Cone Retainer w/Dust (7/32" Cap & x Seal9) Ring 32 Y-708 11000 TL-AF30 Left Hand Inner DustA Cap Installation Tool 19 Y-36U 09000 Right Hand Dust Cap A 16 Y-377 10000 Seal Ring 33 Y-041 20800 Internal Hub Grease (Net. 100g) 20 Y-36U 10000 Chain Guard 17 21Y-32T 08100Y-33R 52001 Left HandRight Inner Hand Dust Dust Cap Cap B A Y-1ZN 98010 Sprocket Wheel 18T w/Guard Plate (CS-S500) A 22 Y-1ZN 98020 Sprocket Wheel 20T w/Guard Plate (CS-S500) A 23 Y-321 20010 Snap Ring C AA 24 Y-220 06010 Washer (3.2 mm) BA 25 Y-200 03000 Hub Nut (9 mm) A 26 Y-33S 98290 Push Rod (90.75 mm) A * 27 Y-6P1 98030 SM-BC06 Bell Crank Unit * 28 Y-33S 98010 Cable Adjusting Bolt & Nut * 29 Y-33S 74000 Bell Crank Body Fixing Bolt * 30 Y-33S 98030 Inner Cable Fixing Bolt Unit * 31 Y-6P1 98040 Bell Crank Cover & Fixing Screw 32 Y-708 11000 TL-AF30 Left Hand Inner Dust Cap Installation Tool A 33 Y-041 20800 Internal Hub Grease (Net. 100g) A A: Same parts. 0807-2723A B: Parts are usable, but differ in materirals, appearance, finish, size, etc. Absence of mark indicates non-interchangeability.

54 Return to index page

NEXUS Revo-Shift Lever (For 3-Speed) SL-3S41E SL-3S42E Spare parts list

NEXUS REVOSHIFT Lever (For 3-Speed) SL-3S41E / SL-3S42E 2

4 1

2 3

6 SM-BC06 SET SET 7

ITEM NO. SHIMANO CODE NO. DESCRIPTION 1 Y-6P1 98010 Cover & Fixing Screw 2 Y-6F0 04000 Cover Fixing Screw SL-8S20 SL-7S20 Bell Crank 4 3 Y-6F4 09000 Clamp Screw (M4 x 23.5) ITEM SHIMANO DESCRIPTION INTERCHANGE- NO. CODEY-65P NO. 03110 Grip for SL-3S41E ABILITY 4 1 Y-6P1Y-6FD98010 14000 Cover & FixingGrip Screw for SL-3S42E 5 2 Y-6F0Y-6P104000 98030 Cover FixingSM-BC06 Screw Bell Crank Unit AA 3 Y-6F4 09000 Clamp Screw (M4 x 23.5) AA 6 Y-33S 98010 Cable Adjusting Bolt & Nut Y-65P 03110 Grip for SL-3S41E 4 7 Y-6FDY-33S14000 74000 Grip for SL-3S42EBell Crank Body Fixing Bolt AB 8 5 Y-6P1Y-33S98030 98030 SM-BC06 BellInner Crank Cable Unit Fixing Bolt Unit 9 6 Y-33SY-6P198010 98040 Cable AdjustingBell CrankBolt & Cover Nut & Fixing Screw A 7 Y-33S 74000 Bell Crank Body Fixing Bolt A 8 Y-33S 98030 Inner Cable Fixing Bolt Unit A 9 Y-6P1 98040 Bell Crank Cover & Fixing Screw A: Same parts. 0707-2730 B: Parts are usable, but differ in materirals, appearance, finish, size, etc. Absence of mark indicates non-interchangeability.

55 Return to index page

Spare parts list

NEXUS REVOSHIFT Lever SL-3S35-E For 3-speed

2 4 1

7 8 9 10 For SG-3R75 11

INSTRUCTIONS

SIS-SP Cable

Be sure to read these instructions carefully before use in order 1.2 to assure correct use. 2000mm mm Cap installation

x100pcs Use the cable cutter (TL-CT10) for installation of the SIS-SPcabie. Cable cutter (TL-CT10)

agonal part of the cable cutter to e liner. (1) Use the cable cutter to cut to the necessary length.

(2) After cutting, use the hex repair the distortion of th 12 If the cap is not securely attached to iutothe liner,the cap, the firmlySIS might not move properly. all thee way cap at the hexagonal part,

(3) Then insert the liner clamp the inner edge of th and then secure it.

SIS-SP Cable Cap

Please note: Specifications are subject to change for improvement without notice. (English) SHIMANO TOTAL 13 INTEGRATION INNER CABLE

SHIMANO TOTAL INTEGRATION INNER CABLE

1.2 mm 2000 mm 7.62 m / 25 ft. 1.2 mm With Outer Caps CJ-NX40 APAN (100 pcs.) ( 6 mm: 30 pcs.) (100 pcs.) J

ITEM NO. SHIMANO CODE NO. DESCRIPTION 1 Y6E898010 Indicator Cover & Fixing Screw (M2.5 x 7) 2 Y65P98040 Indicator 3 Y65U04000 Outer Casing Holder 4 Y6CK10000 Clamp Bolt (M4 x 16) 5 Y65P03110 Shift Actuator (Black) Y61X14000 Half Grip (ø22.2 mm / Gray) 6 Y61X14010 Half Grip (ø22.2 mm / Black) 7 Y60098630 Inner Cable Box (Stainless / 100 pcs.) Y60B98030 SIS-SP Outer Casing (Black) w/Outer Caps 8 Y60B98020 SIS-SP Outer Casing (Silver) w/Outer Caps 9 Y62098030 Inner End Caps (ø1.2 mm / 100 pcs.) 10 Y6SJ98060 Cable Adjusting Bolt Unit & Outer Casing Holder 11 Y61W98030 Cable Adjusting Bolt Unit 12 Y6SJ03000 Outer Casing Holder 13 Y74Y98170 CJ-NX40 Cassette Joint 14 Y74Y98030 Inner Cable Fixing Bolt Unit